Need for Speed™ Common Repairs
040-0196-01 Rev. A
www.globalvr.com
http://service.globalvr.com
[email protected]
Phone: 408.597.3435
Fax: 408.597.3437
Table of Contents
Safety .................................................................2
Environmental Conditions .............................2
Introduction .......................................................3
Force-Feedback Steering System Repairs ........3
ESD Shock Protection for Dual PCB
Systems .................................................5
5 KΩ Steering Pot (Potentiometer)
Replacement..........................................5
Force-Feedback Belt, Gear or Motor
Replacement..........................................6
Force-Feedback PCB Replacement .............. 7
Control Panel Button Service........................... 7
Pedal Assembly Service ................................... 8
5 KΩ Gas and Brake Pot (Potentiometer)
Replacement ......................................... 8
Six-Speed Shifter Replacement........................ 9
Six-Speed Shifter Micro Switch Service ...... 9
Six-Speed Shifter Spring Replacement....... 10
Audio Amp and Speakers Service.................. 11
List of Figures
Figure 1. Dual PCB Force-Feedback
Steering System .....................................4
Figure 2. Single PCB Force-Feedback
Steering System .....................................4
Figure 3. Adding a Ground Wire for ESD
Protection ...............................................5
Figure 4. Replacing the 5 KΩ Steering Pot....6
Figure 5. Servicing the Steering motor ..........7
Figure 6. Button Assembly ............................8
Figure 7. Pedal Assembly Details ..................8
Figure 8. Six-Speed Shifter Gears and
Micro Switch Actuation.......................10
Figure 9. Six-Speed Shifter Spring
Replacement.........................................11
Figure 10. Audio Wiring and Speaker
Locations..............................................11
© 2008 Global VR, Inc. All Rights Reserved. Electronic Arts and Need for Speed are trademarks or registered trademarks of Electronic Arts Inc. in the U.S. and/or other
countries. All rights reserved. GLOBAL VR and the GLOBAL VR logo are registered trademarks of Global VR, Inc. All other trademarks are the property of their
respective owners.
GLOBAL VR IS AN AUTHORIZED ELECTRONIC ARTS DISTRIBUTOR.
Safety
Safety
The following safety instructions apply to all game operators and service personnel. Specific warnings and cautions will
be included throughout this manual.
Use the following safety guidelines to help protect the system from potential damage and to ensure your personal safety:
•
Electronic components in the game cabinet run on 115 VAC. The voltage switch on the back of the computer must
be set to 115. If you power up the computer outside of the cabinet, set the switch to match the local AC voltage:
−
115 volts / 60Hz in most of North and South America and some Far Eastern countries such as Japan, South
Korea and Taiwan
−
230 volts / 50Hz in most of Europe, the Middle East and the Far East
•
To help prevent electric shock, plug the system into a properly grounded power source. These cables are equipped
with 3-prong plugs to help ensure proper grounding. Do not use adapter plugs or remove the grounding prong from
a cable. If you must use an extension cable, use a 3-wire cable with properly grounded plugs.
•
To help protect your system from sudden increases and decreases in electrical power, use a surge suppressor, line
conditioner or Uninterruptible Power Supply (UPS).
•
Be sure nothing rests on the system's cables and that the cables are not located where they can be stepped on or
tripped over.
•
Keep your system far away from radiators and other heat sources.
•
Do not block cooling vents.
CAUTION: GLOBAL VR assumes no liability for any damage or injuries incurred
while servicing the cabinet. Only qualified service personnel should perform service
and installation of cabinet hardware.
To prevent electrostatic discharge (ESD) damage, handle PCBs by the edges only
and use a grounding wrist strap or similar precaution.
Please read the service instructions before working on the cabinet.
Always turn the cabinet OFF and disconnect the AC power cord before performing
any repair work.
Environmental Conditions
Cabinet is intended for indoor use only. Be sure to keep the cabinet dry and maintain operating temperatures of
59°-86° F (15°-30° C).
Need for Speed™ Common Repairs
Page 2 of 11
040-0196-01 Rev. A 6/11/2008
Introduction
Introduction
This document provides maintenance and repair procedures for the driving controls and audio system. For more detailed
information, refer to the System Manual or Service and Repair Manual for your specific cabinet.
Force-Feedback Steering System Repairs
The major components of the force-feedback steering system are listed below. The figures on the
next page show the harnessing of the system.
•
Steering Wheel
•
5 KΩ Steering Pot (Potentiometer)
•
Force-Feedback PCB(s), one of the following:
− Dual PCB system with Force-Feedback PCB (Blue Board, part # COEM-6040-245) and
Force-Feedback Motor Controller PCB (Green Board, part # COEM-6052), connected
with a ribbon cable.
− Single-PCB system (Part #: 990-0040-01). This single PCB is a direct replacement for the
dual PCBs and ribbon cable.
•
+24 VDC Power Supply
•
Steering Motor
The steering pot sends the steering wheel position to the computer, via the PCB, as the player
drives. The computer sends back instructions for controlling the steering motor.
The force-feedback steering system is powered by the +24 VDC power supply. The power
supply connects to the PCB, which routes the power to the force-feedback steering motor.
CAUTION: Do not connect the power supply directly to the steering motor. Doing
this will damage the motor and the power supply.
040-0196-01 Rev. A 6/11/2008
© 2008 Global VR, Inc.
Page 3 of 11
Force-Feedback Steering System Repairs
Figure 1. Dual PCB Force-Feedback Steering System
Figure 2. Single PCB Force-Feedback Steering System
Note: The Single and Dual PCB systems are interchangeable as replacement parts. The Single PCB
system went into production on later Need for Speed™ Underground systems.
Need for Speed™ Common Repairs
Page 4 of 11
040-0196-01 Rev. A 6/11/2008
Force-Feedback Steering System Repairs
ESD Shock Protection for Dual PCB Systems
In some locations, players tend to generate high levels of static electricity that can knock out the
force-feedback steering. The figure below illustrates how to add additional ESD protection to
prevent steering failure in high-static environments. (This fix applies to dual-PCB systems only.)
Figure 3. Adding a Ground Wire for ESD Protection
5 KΩ Steering Pot (Potentiometer) Replacement
You can test the steering pot from the Operator Menu. While turning the wheel, the change in the
numbers displayed onscreen should be smooth and linear, with no jumps.
You can also power off the game and test resistance at the pot. While turning the wheel, you
should see a steady linear increase or decrease in resistance, with no jumps.
To replace a pot, refer to Figure 4 and perform the following steps:
1. Using a 7/64 Allen wrench, loosen the set screw from the steering column and remove the
bracket with the 5 KΩ steering pot attached.
2. Using a 1/2-inch wrench, remove the nut and lock washer from the bracket and remove the pot.
040-0196-01 Rev. A 6/11/2008
© 2008 Global VR, Inc.
Page 5 of 11
Force-Feedback Steering System Repairs
3. Reverse these steps to install the new pot. Install the pot with the plastic pin through the small
hole in the bracket, as shown in Figure 4 below. Make sure the set screw is against the flat part
of the shaft. Tighten the set screw firmly with an Allen wrench and secure with blue Loctite®.
4. Calibrate the steering from the Operator Menu after replacing the pot.
Figure 4. Replacing the 5 KΩ Steering Pot
Force-Feedback Belt, Gear or Motor Replacement
Refer to Figure 4 above, and Figure 5 below, and perform the following steps to remove the
force-feedback belt for repair. Always replace the belt if it looks cracked or worn.
Inspect the belt and the gears, and if any teeth are missing or worn, replace the component. Make
sure the motor gear lines up perfectly with the steering gear to prevent damage to the belt and the
gears.
1. Using a 7/64 Allen wrench, loosen the set screw from the steering column and remove the
bracket with the pot attached (see Figure 4).
2. Using a 10mm socket wrench, loosen the belt tension adjustment bolt several turns until you can
slip the belt off of the motor and steering gears (see Figure 5).
3. Loosen the four (4) 3/8" motor mount Kep nuts that secure the steering motor to the frame (see
Figure 5).
4. To replace the motor, remove the four (4) 3/8" Kep nuts that you loosened in step 2, and remove
the motor.
5. Reverse these steps to re-install the motor and belt. When installing the belt, tighten the tension
adjustment bolt until the belt is fully stretched, and then loosen the bolt by ½ turn. Make sure the
motor gear lines up perfectly with the steering gear to avoid damaging the belt and the gears.
Tighten all set screws firmly with an Allen wrench and secure with blue Loctite.
6. Calibrate the steering from the Operator Menu after servicing the belt or motor.
Need for Speed™ Common Repairs
Page 6 of 11
040-0196-01 Rev. A 6/11/2008
Control Panel Button Service
Figure 5. Servicing the Steering motor
Force-Feedback PCB Replacement
CAUTION: To prevent electrostatic discharge (ESD) damage, handle PCBs by the
edges only and use a grounding wrist strap or similar precaution.
If the steering pulls to one side, this could indicate a bad force-feedback motor controller PCB.
Use the following steps to replace one or both force-feedback PCBs.
Important: Part #: 990-0040-01 is a single-PCB system that replaces both COEM-6052 and
COEM-6040-245.
1. Disconnect the cabinet from AC power.
2. Disconnect all cables from the PCB.
3. Remove the four screws that secure the PCB to the cabinet.
4. Reverse these steps to install the new PCB.
5. Calibrate all analog inputs from the Operator Menu after replacing the PCBs.
Control Panel Button Service
Refer to Figure 6 and perform the following steps to replace the button bulbs or micro switches:
1. Disconnect the cabinet from AC power.
2. Open the driving control panel assembly (or, to replace the E-brake button, remove the shifter
assembly from the housing as described on page 9).
Note: Make sure the steering pot cable has enough slack that it doesn't get pulled and broken
when the panel opens.
3. To remove a micro switch, gently rock it to the side and remove it from the housing. Remove
the wires and install them on the same connectors on the new micro switch.
4. To replace a bulb, gently rock the white plastic bulb housing from side to side to pop it out of the
button housing.
5. The buttons are lit with 5-volt C555 bulbs. To remove a bulb, pull it straight out of the housing.
CAUTION: Do not connect the 5-volt lamp power wire to the micro switch. Doing
so can damage the USB I/O card in the computer.
040-0196-01 Rev. A 6/11/2008
© 2008 Global VR, Inc.
Page 7 of 11
Pedal Assembly Service
6. When connecting the wiring to the micro switch and bulb, refer to the labels on the wires to
make sure the connections are correct.
Figure 6. Button Assembly
Pedal Assembly Service
Perform the following steps to remove the pedal assembly. It is removed and installed as one unit.
1. From inside the cabinet, disconnect the pedal cable assembly connector.
2. Remove the four (4) 1/4-20H Torx Security Pedal Assembly Mounting Bolts, shown by the
arrows in the picture below.
3. Pull the pedal assembly towards the seat to remove.
Figure 7. Pedal Assembly Details
5 KΩ Gas and Brake Pot (Potentiometer) Replacement
You can test a pot from the Operator Menu. When you press and release the pedals, you should
see a steady increase or decrease in the numbers displayed onscreen, with no jumps. None of the
values displayed should read zero (0) or 255; if they do you need to adjust the pot.
You can also power off the game and test resistance at the pot. When you press and release the
pedals, you should see a steady linear increase or decrease in resistance, with no jumps.
To replace a pot, refer to Figure 7 above and perform the following steps:
Need for Speed™ Common Repairs
Page 8 of 11
040-0196-01 Rev. A 6/11/2008
Six-Speed Shifter Replacement
1. Using a 7/64 Allen wrench, loosen the set screw from the gear wheel and remove the gear wheel,
as shown in Figure 7.
2. Using a 1/2" wrench, remove the nut and lock washer that secure the pot to the frame.
3. Install the new pot with the same orientation. Make sure that the plastic keys on the pot match
with the metal.
4. Re-install the lock washer and nut, being careful not to over-tighten.
5. Re-install the gear wheel. Make sure the set screw is against the flat part of the shaft. Tighten
the set screw firmly with an Allen wrench and secure with blue Loctite.
6. Calibrate all analog inputs from the Operator Menu after replacing the pot.
Six-Speed Shifter Replacement
Perform the following steps to remove the shifter from the seat for replacement or repair.
1. Remove the four (4) T-10H Security Torx screws from the top of the shifter assembly and
carefully pull the shifter up out of the housing.
2. Disconnect the Molex connector from the shifter.
3. Reverse these steps to re-install the shifter. Make sure that none of the shifter wires are pulled or
pinched in the housing, and there is some slack in the wires so they are not pulled as you shift.
Six-Speed Shifter Micro Switch Service
The shifter uses four miniature micro switches to relay the shifter position to the computer.
Figure 8 shows micro switch placement, and which micro switches are actuated for each gear. By
using the chart, you can determine which switch may be faulty. For example, if gears 1 and 2
stop working, the problem is probably with the Left micro switch.
Note: In Need for Speed™ Underground, the Controls screen in the Operator Menu also displays
which micro switches are actuated as you shift through the gears.
040-0196-01 Rev. A 6/11/2008
© 2008 Global VR, Inc.
Page 9 of 11
Six-Speed Shifter Replacement
Figure 8. Six-Speed Shifter Gears and Micro Switch Actuation
Perform the following steps to replace a micro switch:
1. Remove the shifter assembly from the housing as described on page 9.
2. Disconnect the two wires from the micro switch.
3. Remove the two screws that secure the micro switch to the shifter and remove the switch.
4. Reverse these steps to install the new micro switch.
Note: Make sure there is some slack in the wires so they are not pulled as you shift.
Six-Speed Shifter Spring Replacement
If the shifter does not stay in gear, the spring has probably broken and should be replaced:
1. Remove the shifter assembly from the housing as described on page 9.
2. Make a note of how the components are assembled, and then remove the E-Ring and Screw
shown in Figure 9, and remove the spring and flat washers.
3. Reverse the disassembly steps to re-assemble the shifter.
Need for Speed™ Common Repairs
Page 10 of 11
040-0196-01 Rev. A 6/11/2008
Audio Amp and Speakers Service
Figure 9. Six-Speed Shifter Spring Replacement
Audio Amp and Speakers Service
The u5.1 audio amp supports 6-channel 5.1 Surround Sound. The audio amp PCB is powered by
the +5/+12 volt DC power supply through a standard PC power connector. A fuse is installed on
the PCB to help prevent electrical damage to the PCB.
The volume level for each channel on the audio amp can be manually adjusted using a small
screwdriver to turn the Adjustment Pots, shown in Figure 10. For best results, turn each pot
counterclockwise to turn the volume levels all the way down. Next, turn each pot 1/5 of a turn
clockwise to bring the audio levels up. You can fine-tune the sound levels for your location from
this point.
The figure below illustrates audio wiring and speaker locations.
Figure 10. Audio Wiring and Speaker Locations
040-0196-01 Rev. A 6/11/2008
© 2008 Global VR, Inc.
Page 11 of 11